Hot Crack Filling
Cracks are the entry point for water, the primary cause of asphalt failure. Hot-pour crack filling seals those entry points before freeze-thaw cycles turn small cracks into large failures.
Why Crack Filling Matters
Asphalt cracks are inevitable. Thermal expansion and contraction, tree root pressure, heavy vehicle loads, and the natural aging of the binder all produce cracks over time. Left untreated, even a hairline crack becomes a water channel. In Westchester County's climate, that water freezes, expands, and widens the crack with every winter cycle — a process that accelerates exponentially once it begins.
Hot-pour crack filling is the industry standard for addressing cracks before they reach the sub-base. A rubberized, hot-applied sealant is poured directly into the crack, where it bonds to both sides and remains flexible through temperature extremes. Unlike cold-pour products available at hardware stores, hot-pour material does not shrink, crack, or debond over time.
Crack filling is always performed before sealcoating. Sealing over open cracks traps moisture and accelerates deterioration — the correct sequence is always fill first, then seal.
Benefits of Hot-Pour Crack Filling
Stops Water Infiltration
Seals the crack completely, preventing water from reaching the sub-base where it causes heaving, frost damage, and base failure.
Flexible in Cold Weather
Hot-pour rubberized sealant remains flexible at sub-zero temperatures, moving with the pavement rather than cracking under thermal stress.
Long-Lasting Bond
Properly applied hot-pour material bonds chemically to the asphalt on both sides of the crack, lasting 3–5 years before re-treatment is needed.
Prevents Crack Widening
Filled cracks do not widen. Unfilled cracks typically double in width each winter, eventually requiring cut-and-patch or full resurfacing.
Cost-Effective Maintenance
Crack filling costs a fraction of what pothole repair or resurfacing costs. It is the highest-ROI maintenance task for any asphalt surface.
Required Before Sealcoating
Crack filling is a prerequisite for sealcoating. Addressing cracks first ensures the sealcoat performs as intended and lasts its full service life.
Our Crack Filling Process
Crack Assessment
We measure crack width and depth to determine whether hot-pour filling is appropriate or whether the damage requires cut-and-patch repair. Cracks wider than 1.5 inches typically require patching.
Crack Cleaning
Cracks are blown clean with compressed air to remove loose debris, vegetation, and moisture. Clean cracks are essential for proper adhesion of the hot-pour material.
Hot-Pour Application
Rubberized crack filler is heated to 375–400°F and poured directly into the crack using a pour pot or wand applicator. The material flows into the crack and bonds to both walls.
Squeegee and Level
Excess material is squeegeed flush with the surface to create a smooth, level repair that does not create a trip hazard or collect water.
Cool and Cure
Hot-pour material cools and becomes traffic-ready within 20–30 minutes. No extended cure time is required before vehicle traffic.
Frequently Asked Questions
What is the difference between hot-pour and cold-pour crack filler?
Hot-pour material is heated to 375–400°F and applied as a liquid that bonds chemically to the asphalt. Cold-pour products from hardware stores are pre-mixed emulsions that shrink as they cure, often debonding within one or two winters. Hot-pour is the professional standard.
How wide can a crack be before it needs to be patched instead of filled?
Cracks up to about 1.5 inches wide can typically be filled with hot-pour material. Wider cracks, or cracks with significant edge deterioration, require cut-and-patch repair to restore structural integrity.
How long does crack filling last?
A properly applied hot-pour crack fill typically lasts 3–5 years. Cracks in high-traffic areas or areas subject to significant thermal movement may require re-treatment sooner.
Should I fill cracks before or after sealcoating?
Always before. Sealcoating over open cracks traps moisture and prevents the sealcoat from bonding properly at the edges. The correct sequence is: fill cracks, allow to cure, then sealcoat.
Can crack filling be done in cold weather?
Hot-pour crack filling requires pavement temperatures above 40°F for proper adhesion. We do not perform crack filling in freezing conditions or when rain is forecast within 24 hours.
Stop Cracks Before They Become Failures
Get a free, no-obligation estimate. We serve residential and commercial properties throughout Westchester and Fairfield counties.